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IMO Precision Controls

PLC Training Manual

G-Series Basic PLC Training IMO Precision Controls 1000 North Circular Rd Staples Corner London NW2 7JP Tel: +44 (0) 208 452 6444 Fax: +44 (0) 208 450 2274 Email: [email protected] or [email protected] Web: www.imopc.com

IMO Precision Controls

IMO Precision Controls 1000 North Circular Rd Staples Corner London NW2 7JP Tel: +44 (0) 208 452 6444 Fax: +44 (0) 208 450 2274 Email: [email protected] or [email protected] Web: www.imopc.com

IMO Precision Controls G-SERIES PLC RANGE

1

RANGE OVERVIEW PART NUMBERING

1 6

INSTALLATION OF IMO GMWIN

7

INTRODUCTION TO GMWIN

10

STARTING A NEW GMWIN PROJECT

12

NAVIGATING GMWIN

15

SETTING UP THE PC CONNECTION FOR PROGRAMMING GMWIN MENU’S PROJECT MENU PROGRAM MENU EDIT MENU VIEW MENU COMPILE MENU ONLINE MENU TOOLS MENU WINDOW MENU HELP MENU PROJECT TREE PARAMETER LIST LIBRARY MENU OUTPUT WINDOW

16 18 18 18 19 19 19 20 20 20 21 22 22 23 23

ADDRESSING IN A G-SERIES PLC

24

MEMORY ALLOCATION IN G-SERIES PLC

26

BITS AND BYTES

27

LADDER PROGRAMMING RULES

28

VARIABLE DECLARATION

31

TIME VARIABLES

33

BASIC LADDER LOGIC

34

INPUTS AND OUTPUTS INPUTS OUTPUTS

34 34 35

IMO Precision Controls BOOLEAN LOGIC LATCHING CIRCUITS FLIP / FLOP CIRCUIT LADDER PROGRAMMING EXAMPLE

35 36 36 37

BASIC FUNCTIONS

41

MOVE FUNCTION ARITHMETIC FUNCTIONS ADD FUNCTION SUB FUNCTION MUL FUNCTION DIV AND MOD FUNCTION BIT FUNCTIONS AND, OR, XOR FUNCTIONS SHIFT AND ROTATE FUNCTIONS COMPARE FUNCTIONS LT, EQ, AND GT FUNCTIONS FUNCTION PROGRAMMING EXAMPLE

42 42 43 43 44 45 46 46 48 48 49 51

BASIC FUNCTION BLOCKS

61

TIMER FUNCTION BLOCKS TOF, OFF DELAY TIMER. TON, ON DELAY TIMER. TP, TIMER PULSE. COUNTER FUNCTION BLOCK CTU, UP COUNTER. CTD, DOWN COUNTER CTUD, UP / DOWN COUNTER. FUNCTION BLOCK PROGRAMMING EXAMPLE

62 63 63 64 65 65 66 67 68

MULTIPLE-SOURCE PROGRAMMING

74

GLOBAL VARIABLES MULTIPLE LD PROGRAMS SUBROUTINES

74 76 78

DOWNLOADING AND ONLINE OPTIONS

80

COMPILING AND BUILDING GMWIN SIMULATION DOWNLOADING

80 81 83

BASIC COMMUNICATION

86

G7 PLC COMMUNICATION DIP SWITCH SETTING

88

IMO Precision Controls PROGRAMMING TUTORIAL EXAMPLE – WASHING MACHINE

90

SPECIFICATION 90 MACHINE I / O 90 WASHING MACHINE CYCLES 90 THE PROGRAM CYCLE 91 BEGINNING TO PROGRAM 91 1. WHITE WASH OR COLOUR WASH IS SELECTED BY A ROTARY SWITCH. 94 2. WHEN THE LID IS CLOSED AND THE START BUTTON IS PRESSED, DETERGENT + WATER ARE PUMPED IN FOR 1 MINUTE 97 3. THE DRUM ROTATES FOR THE SPECIFIED WASH TIME, DEPENDING ON THE TYPE OF WASH SELECTED. 99 4. THE DRUM IS DRAINED FOR 1 MINUTE. 100 5. FRESH WATER IS POURED IN FOR 1 MINUTE. 100 6. THE DRUM IS ROTATED FOR THE SPECIFIED RINSE TIME , DEPENDING ON THE TYPE OF WASH SELECTED. 101 7. THE WATER IS DRAINED FOR 1 MINUTE. 101 8. THE DRUM IS ROTATED FOR THE SPECIFIED SPIN TIME , DEPENDING ON THE TYPE OF WASH SELECTED. 102 9. THE LID OPEN LAMP WILL OPERATE IF THE LID IS OPENED, AND THE WASH SEQUENCE CANNOT START . 102 10. IF THE LID IS OPENED AT ANY TIME DURING THE WASH CYCLE, THE CYCLE IS SUSPENDED AND ONLY CONTINUES WHEN THE LID IS CLOSED AGAIN. 103 COMPILE AND BUILD THE PROJECT 105 SIMULATE THE PROGRAM 105 DOWNLOAD THE PROGRAM TO THE PLC 106 TUTORIAL 1 – IMO GREENHOUSE

109

TUTORIAL 2 – IMO CAR PARK

110

TOPICS COVERED IN THE ADVANCED COURSE

111

IMO Precision Controls 1000 North Circular Rd Staples Corner London NW2 7JP Tel: +44 (0) 208 452 6444 Fax: +44 (0) 208 450 2274 Email: [email protected] or [email protected] Web: www.imopc.com

IMO Precision Controls

G-Series PLC Range IMO’s G-series PLC range covers the complete scope of automation potential. Within the IMO PLC range there are three levels. What determines these levels generally is the users requirements for the application such amount of I/O required. The IMO range begins with the expandable brick type PLC, the G7 series. To the compact, slot and rack in the mid-range, the G6 series, through to the high-end G4 series. From the 10 I/O brick style G7 to the 1024 I/O Multi-rack and slot G4 PLC, IMO have got it covered! The complete G-Series range is programmed through the IEC61131-3 compliant software. This is a windows based program allowing the user to program in Ladder diagram (LD), Sequential Function Chart (SFC) and Instruction List (IL).

Range Overview

G7 Power Supply

I/O

Analogues

Comm. options

Expansion

Additional features

Programming Software

110/230Vac or 24Vdc (E-marked for vehicle low voltage (12V) operation)

G6

G4

110/230Vac or 24Vdc (E-marked for vehicle low voltage (12V) operation)

110 Vac or 230Vac or 24Vdc

Up to 384

Up to 1024

G6F-AD2A 4 analogue inputs. Selectable, 4-20mA, 0-20mA or 0-10V G6F-DA2V voltage input G6FDA2I current input

G4F-AD2A 4 analogue inputs. Selectable, 4-20mA, 0-20mA or 0-10V G4F-DA2V voltage input G4FDA2I current input

RS232 and RS485 options. Modbus, Profibus, DeviceNet, FNet, RNet (IMO comms). Ethernet. User defined comms.

RS232 and RS485 options. Modbus, Profibus, DeviceNet, FNet, RNet (IMO comms). Ethernet, User defined comms.

Maximum rack size of 12 slots. Non-expandable.

Maximum rack size of 8. 3 expansion racks of 8. Totalling 32 slots.

17k steps. Dedicated MPU 0.5µs. 3-axis open loop position control module. 3 options of CPU.

32k steps. Dedicated MPU 0.2µs. Floating-point maths & USB programming port option. PID module with 8 separate PID loops. GMWin. IEC61131-3 (LD/IL/SFC)

Up to 80

Two analogue modules: 2 in, 1 out. Or 4 in. Voltage or Current selectable. 2 inbuilt RS232 user configurable ports. RS232 and RS485 options. Modbus, Profibus (slave), DeviceNet (slave) FNet, RNet (IMO comms). User defined comms. Up to 3 maximum but only 2 of the 1 kind. I.e. 2 analogue modules + 1 relay module. HSC, RTC module, 7k steps, addition memory module & built in PID.

GMWin. IEC61131-3 (LD/IL/SFC)

GMWin. IEC61131-3 (LD/IL/SFC)

Page 1

IMO Precision Controls • • • •

All of the IMO G-series range uses the same programming software, the IEC61131-3 compliant: GMWin. All the PLC’s can be interlinked and share data within their own dedicated network. The slot and rack PLC’s are modular and very variable. They can be specified to meet the application more precisely. The I/O count doesn’t include the remote I/O units. A maximum network size of 64 stations, with each possibly having 32 points. (I/O = 2048)

Page 2

IMO Precision Controls

IMO G7

The IMO G7 is a very compact block style programmable controller offering extremely high performance. It is ideal for all applications from process control to machine control • Up to 80 I/O • High speed processing 0.5µsec per step • Memory capacity 68K bytes • Conforms to elements of the IEC61131-3 (IL/LD/SFC) • Built in PID, interrupt, pulse count and input filters • High speed counter input 16kHz, 8kHz two phase • RTC option and memory module options • Fieldbus options FNet (master/slave), DeviceNet (slave) and Profibus (slave) • Two built in RS232 serial ports one dedicated the other user configurable • Two analogue modules: 2 / 1 analogue i/o or 4 analogue inputs • Analogue potentiometer module • 10 I/O expansion module • RS232 and RS485 option modules • Uses the same programming software as G6 & G4 (GM-WIN) • Conforms to CE and UL

Page 3

IMO Precision Controls

IMO G6

The IMO G6 is a compact modular programmable controller offering extremely high performance. It is ideal for all applications from process control to machine control • • • • • • • • • •

Up to 384 I/O High speed processing with dedicated MPU 0.5µsec per step Memory capacity 17Ksteps Conforms to elements of the IEC1131-3 standard (IL/LD/SFC) PID control, computer link, high speed counter and RTC CPU options are available Fieldbus option 1Mbps (FNet), DeviceNet, and Profibus options Computer link module for linking up to 32 PLCs to a computer, or to other devices by easily configuring user protocols Wide range of digital and analogue I/O High speed counter module Conforms to CE requirements

YEAR GUARANTEE

Page 4

IMO Precision Controls

IMO G4

The IMO G4 is a modular programmable controller offering extremely high performance. It is ideal for all applications from process control to machine control. • • • • • • • • •

Up to 1024 I/O Very high speed processing with custom gate array 0.2µsec per step Memory capacity 32K steps Conforms to elements of the IEC1131-3 standard (IL/LD/SFC) Many special function modules – PID, Analogue timer, High Speed Counter, Positioning, Interrupt and A/D and D/A modules Wide range of communication options – ENet (Ethernet), FNet Fieldbus), Cnet (Computer Link), DNet (DeviceNet) and remote I/O Conforms to CE requirements

YEAR GUARANTEE

Page 5

IMO Precision Controls

Part Numbering At IMO we use an understandable part number where each element has a meaning and is reused through out the part numbering system, thus making it easy to put together product requirements

G M 7 – D _ _ _ A (/ DC – E)

G7 Base models:

R – Relay o/p T – Transistor o/p

DC – 24V DC power

DC power supply. E marked for vehicle applications

G 7 _ – _ _ _ _ (– E)

G7 Expansion modules:

E – Expansion digital I/O F- Special function units L- Communication units

I/O 10 20 30 40 60

DR -Relay DT - Transistor AD - Analogue AT - Ana pot CU – Comm. link RT - RTC DB - DeviceNet PB - Profibus RU - RNet

G4/G6 CPU, Base and Power models:

4 – G4 6 – G6

10A - I/O 2A - 4 A/D HA - 2 A/D, 1 D/A EB - RS232 EC - RS485 EA - Comms

GM_–____

CPU - CPU PAF - Power AC PDF - Power DC B - Base

CPU A – Standard B – A + RS485 port, PID, RTC C – A + HSC, PID G4 C – Floating-point maths Power A – For use with Standard I/O

B – For use with analogue I/O C – For use with 12-slot rack Base 04, 06, 08, 12 M G4/G6 I/O modules:

4 – G4 6 – G6

G__–____

I - Digital Input Q - Digital Output F - Special function units L - Communication units

RY2A –16 Relay o/p D22A – 16 DC i/p D24A – 32 DC i/p A21A –230 AC i/p A11A - 110 AC input AD2A – 4 Analogue i/p TR2A – 16 Trans o/p TR4A – 32 Trans o/p

HSCA – HSC POPA – Position control FUEA – FNet PUEB – Profibus EUTB – Ethernet CUEC – RS485 Comm. CUEB – RS232 Comm. Plus many more options

Page 6

IMO Precision Controls

Installation of IMO GMWin GMWin can be obtained on the IMO PLC Software CD or can be downloaded from the website: www.imopc.com free of charge. To install double click on the icon GMWIN4.exe and follow the instructions.

A dialogue box showing the welcome message appears. It is required to exit any other windows application programs that may be running during the installation of GMWIN.

Click Next to move to the next screen.

Page 7

IMO Precision Controls

Select the destination folder for GMWin to be installed into. If [Browse] is clicked then a dialogue box will appear for the path to be inputted. Select the path to install to or manually write the path in the box and click [OK].

After selecting the path to install, click [Next].

After confirming the path to install into, click [Next] to continue. Page 8

IMO Precision Controls GMWin will then begin to install on your computer, in the directory specified.

When the install is completed, it is required to restart your computer. You have the option to restart your computer now or later from the following screen.

Now that the installation is complete and after you have restarted your computer, click on the GMWin icon to start programming.

Page 9

IMO Precision Controls

Introduction to GMWin GMWIN is a programming and debugging tool for the full range of G-Series PLC’s (G7, G6 and G4). It is an IEC61131-3 programming compliant environment and with three different programming languages, IL, SFC and Ladder.

Ladder

SFC

IL

Programs can be created with clear symbols for easy understanding and easy to follow menus to create functions and variables alike.

GMWin complies with the standardising of expressing direct variables by I, Q, M (Input, Output, Memory). The allocation of program variable memory is carried out automatically or by the user designation. Various data type and kinds can be selected to match the variables requirements. It is also possible to set the initial value, and add documentation to every function, function block, constant and variable.

Page 10

IMO Precision Controls The IMO G-Series is a Project based PLC system. In GMWin it is possible to create several different dedicated programs in different languages to perform specific routines and have them all related in a Project. As well as Programs there is the option of Tasks, which can be time or event driven.

A project tree is shown above that details all libraries, tasks and programs included in a project. Project based programs make duplication and re-use of programs quick and easy. It is possible to not only download and monitor programs directly connected to a PC but also for PLC’s connected in a network. When connected with a PLC it is possible to monitor the operation, change the mode and edit online. Online editing, allows the PLC to remain running and the program can be changed. The full PLC mode, error state and parameters can also be read when connected. It is also possible to create User-Defined Functions and Function Blocks. This allows for frequently used bits of code being made into an easy to use and re-useable graphical function block. There is also the utility to create User-Defined Communication Protocols, thus allowing obscure and bespoke devices to be communicated with.

Page 11

IMO Precision Controls

Starting a new GMWin Project To start a new program click on the GMWin icon.

This is located in the path that is specified during installation or you can create a desktop shortcut.

Click start and then All Programs

This box pops up whilst the GMWin program is initialising.

GMWin will appear, with the last project that you were working on, if you did not close the program down. At the moment GMWin will have no project and look rather empty, as this is the first run of the software on your computer.

Page 12

IMO Precision Controls To begin a New Project, either click the New Project icon or select the option from the drop down Project menu.

In this first menu we can enter the project details and where the project folder is going to be created. We must select the PLC we are going to use and we have some documentation options.

Page 13

IMO Precision Controls

The next stage is to define the first program. This can be edited later and even removed but initially this must be set up. The program will initially be called noname.src, but to modify this, simply highlight the area shown and enter a name that has more meaning to your application.

Next we have to select what language we are going to write the program in. The default is ladder. SFC, LD and IL will be discussed in more detail later. There is also an opportunity to add further documentation notes.

Clicking [Finish] will complete the set up process and return you to the main Window with a fuller Project to begin programming.

Page 14

IMO Precision Controls

Navigating GMWin GMWin is a “windows” based programming environment and it can be daunting at first with the amount of information on offer. The programming environment can be customised to your personal preference, with windows an optional buttons being selectable.

Programming window. It is here where the ladder logic is entered

Project tree

Variable table. The table builds up as the more variables are used in the p rogram.

Ladder logic functions (When programming in ladder)

Project, parameter & library tabs.

Output window. In this window error messages and compile warnings can be found

Connection status

Page 15

IMO Precision Controls

Setting up the PC connection for programming The most important thing to do first is to ensure that the correct communication port is selected in GMWin to connect with a PLC. This is particularly important if you are using a USB to Serial converter. It is possible to locate your computers communication ports using the Device Manager in Windows Control panel. (Control Panel: System, Hardware; Device Manager).

The Device Manager can be found in the Control Panel, System, Hardware. Your IT manager should be consulted before altering System configurations.

This computer has a serial port addressed on communication port COM1.

To ensure that the correct port is selected in GMWin go to the option menu in the Project drop down list.

There is a USB option with the G4 series CPUC

Select the Connection Option tab.

Page 16

Programming port selection. Drop down tab

IMO Precision Controls The standard method of connection is RS-232C; this is a standard 3 wire, 9 pin D-type connector crossover cable (KIC-50A). Select the communication port that you are going to use from the drop down list.

Page 17

IMO Precision Controls

GMWin Menu’s Project Menu The project menu has the options required to manage the complete project. Starting a new project, opening an existing project, saving and uploading from a PLC (to be discussed latter). Project bundles are the best method for transporting GMWin PLC projects. It collates all the files into one easy to transfer .MUK file. Print options GMWin options Previous projects created.

Program Menu This menu operates the options required for the programs in a project. A GMWin project is made up of two types of files. A .prj file that contains the project information and at least one .src source file that contains the program information.

Page 18

IMO Precision Controls

Edit Menu In this menu there are the options to edit the programs. In this menu the options can be found to edit programs.

Ladder logic programming tools (discussed later)

View Menu Using the options in this menu you can customise what windows you want to view.

Select or deselect to view the Project and output window View the documentation added with the memory address

Compile Menu This menu is used to build and compile the program writ...